Air and Hydraulic, Heated, Plural Component Proportioners For spraying polyurethane foam and polyurea coatings. Not for use in explosive atmospheres.

Operation 309812G Air and Hydraulic, Heated, Plural Component Proportioners For spraying polyurethane foam and polyurea coatings. Not for use in explosive atmospheres. Important Safety instructions. Read all warnings and instructions in this manual. Save these instructions. See Models, page 3. TI3699b

Contents Models................................... 3 Manual Conventions........................ 3 Supplied Manuals.......................... 4 Related Manuals........................... 5 Warning................................... 6 Typical Installation, with circulation........... 8 Typical Installation, without circulation........ 9 Component Identification................... 10 Controls and Indicators.................... 11 Isocyanate Hazard......................... 13 Moisture Sensitivity of Isocyanates........... 13 Spray Adjustments........................ 13 Setup.................................... 14 Startup.................................. 23 Spraying................................. 26 Shutdown................................ 28 Pressure Relief Procedure.................. 29 Fluid Circulation........................... 30 Diagnostic Codes.......................... 33 Maintenance.............................. 34 Flushing................................. 35 Accessories.............................. 36 Dimensions............................... 37 Technical Data............................ 38 Graco Standard Warranty................... 40 Graco Information......................... 40 2 309812G

Models Models Air Powered Reactors A-XP SERIES Part No. Series Model Heat Packages (do not include proportioner) HT SERIES Voltage (phase) Heater Watts (no hose) Flow gpm (lpm) at 78 cpm Output per Cycle (A + B) gal. (liter) Pressure Ratio Maximum Fluid Working Pressure psi (MPa, bar) 246639 B A-XP2 230V (1) 10,200 1.5 (5.7).0193 (.073) 25:1 3000 (20.7, 207) 246752 B A-XP2 230V (3) 10,200 1.5 (5.7).0193 (.073) 25:1 3000 (20.7, 207) 246753 B A-XP2 380V (3) 10,200 1.5 (5.7).0193 (.073) 25:1 3000 (20.7, 207) Part No. Series Model Voltage (phase) Heater Watts (no hose) 246365 D HT-6.0 230V (1) 6,000 246760 D HT-6.0 230V (3) 6,000 246761 E HT-6.0 380V (3) 6,000 246607 D HT-10.2 230V (1) 10,200 246762 D HT-10.2 230V (3) 10,200 246763 E HT-10.2 380V (3) 10,200 246364 D HT-15.3 230V (1) 15,300 246764 D HT-15.3 230V (3) 15,300 246765 E HT-15.3 380V (3) 15,300 TI3707a Manual Conventions Warning WARNING A warning alerts you to possible serious injury or death if you do not follow instructions. Symbols, such as fluid injection (shown), alert you to a specific hazard and direct you to read the indicated hazard warnings on pages 6-7. Caution CAUTION A caution alerts you to possible equipment damage or destruction if you do not follow instructions. Note A note indicates additional helpful information. 309812G 3

Supplied Manuals Supplied Manuals The following manuals are shipped with the Reactor. Refer to them for detailed equipment information. Order Part No. 15B535 for a compact disk of Reactor manuals translated in several languages. Air and Hydraulic Reactors Part No. Description 309813 Air and Hydraulic Reactors, Repair-Parts Manual (English) Proportioning Pumps (one of following included) Part No. Description 308224 President Pump (Models A-25 and A-XP2), Repair-Parts Manual (English) 307547 King Pump (Model A-50), Repair-Parts Manual (English) 307547 Viscount Pump (Models H-50 and H-XP3), Repair-Parts Manual (English) Motors (one of following included) Part No. Description 306982 President Air Motor (Models A-25 and A-XP2), Repair-Parts Manual (English) 309347 King Air Motor (Model A-50), Repair-Parts Manual (English) 307158 Viscount Hydraulic Motor (Models H-50 and H-XP3), Repair-Parts Manual (English) Displacement Pumps (one of following included) Part No. Description 307430 Displacement Pumps (Models A-25, A-XP2, and H-XP3), Repair-Parts Manual (English) 307944 Displacement Pumps (Models A-50 and H-50), Repair-Parts Manual (English) Reactor Electrical Diagrams (one of following included) Part No. Description 309854 Electrical Diagrams, 230V 1 phase 309855 Electrical Diagrams, 230V 3 phase 309576 Electrical Diagrams, 380V 3 phase Air Regulators (air powered units only) Part No. Description 308168 Instruction-Parts Manual (English) 4 309812G

Related Manuals Related Manuals The following manuals are for accessories used with the Reactor. Order Part No. 15B535 for a compact disk of Reactor manuals translated in several languages. Order Part No. 15B381 for a compact disk of Fusion manual translated in several languages. Hydraulic Power Supply Part No. Description 307550 Instruction-Parts Manual (English) Feed Pump Kits Part No. Description 309815 Instruction-Parts Manual (English) Air Supply Kit Part No. Description 309827 Instruction-Parts Manual (English) for Feed Pump Air Supply Kit Circulation and Return Tube Kits Part No. Description 309852 Instruction-Parts Manual (English) Heated Hose Part No. Description 309572 Instruction-Parts Manual (English) Fusion Air Purge Spray Gun Part No. Description 309550 Instruction-Parts Manual (English) Fusion Mechanical Purge Spray Gun Part No. Description 309856 Instruction-Parts Manual (English) Circulation Kit Part No. Description 309818 Instruction-Parts Manual (English) Data Reporting Kit Part No. Description 309814 Instruction-Parts Manual (English) 309812G 5

Warning WARNING SKIN INJECTION HAZARD High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment. Do not point the gun at anyone or at any part of the body. Do not put your hand or fingers over the gun fluid nozzle. Do not stop or deflect leaks with your hand, body, glove, or rag. Do not blow back fluid; this is not an air spray system. Follow Pressure Relief Procedure, page 29, when you stop spraying and before cleaning, checking, or servicing equipment. Use lowest possible pressure when flushing, priming, or troubleshooting. Engage spray gun piston safety lock when not spraying. Tighten all fluid connections before operating the equipment. Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. High pressure hose cannot be recoupled; replace the entire hose. FIRE, EXPLOSION AND ELECTRIC SHOCK HAZARD Solvent and fumes in work area can ignite or explode. High voltage components can cause electric shock. To help prevent fire, explosion, and electric shock: Shut off main power switch and wait 5 minutes before opening Reactor cabinet door. All electrical wiring must be done by trained and qualified personnel and comply with all local codes. Ground equipment and conductive objects. See Ground system, page 22. Use equipment only in well ventilated area. Eliminate all ignition sources, such as pilot lights, cigarettes and plastic drop cloths (potential static arc). Do not plug or unplug power cords or turn lights on or off when flammable fumes are present. Keep the work area free of debris, including solvent, rags, and gasoline. Hold gun firmly to side of grounded pail when triggering into pail. Use only grounded hoses. If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until you identify and correct the problem. To avoid chemical reaction and explosion, do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents in pressurized aluminum equipment. 6 309812G

Warning WARNING EQUIPMENT MISUSE HAZARD Misuse can cause serious injury or death. For professional use only. Use equipment only for its intended purpose. Call your Graco distributor for information. Read manuals, warnings, tags, and labels before operating equipment. Follow instructions. Check equipment daily. Repair or replace worn or damaged parts immediately. Do not alter or modify equipment. Use only Graco parts and accessories. Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. See Technical Data in all equipment manuals. Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all equipment manuals. Read fluid and solvent manufacturer s warnings. Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not use hoses to pull equipment. Comply with all applicable safety regulations. BURN HAZARD This equipment is used with heated fluid, which can cause equipment surfaces to become very hot. To avoid severe burns: Do not touch hot fluid or equipment. Allow equipment to cool completely before touching it. Wear gloves if fluid temperature exceeds 110 F (43 C). TOXIC FLUID OR FUMES HAZARD Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed. Read Material Safety Data Sheet (MSDS) to know the specific hazards of the fluids you are using. Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines. PERSONAL PROTECTIVE EQUIPMENT You must wear proper protective equipment when operating, servicing, or when in the operating area of the equipment to help protect you from serious injury, including eye injury; inhalation of toxic fumes; and hearing loss. This equipment includes but is not limited to: Protective eyewear. Gloves, clothing, and respirator as recommended by the fluid and solvent manufacturer. Hearing protection. 309812G 7

Typical Installation, with circulation Typical Installation, with circulation Key for FIG. 1 A Air Powered Reactor B Heated Hose (see page 36) C Fluid Temperature Sensor (FTS) D Heated Whip Hose (see page 36) E Fusion Spray Gun (see page 36) F Gun Air Supply Hose G Feed Pump Air Supply Lines (part of Air Supply Kit, page 36) J Fluid Supply Lines K Feed Pumps (see page 36) S L Agitator M Desiccant Dryer (part of Return Tube Kit, page 36) P Gun Fluid Manifold (part of Fusion gun) Q Air Quick-Disconnect (part of Circulation Kit, page 36) R Air Purge Lines (part of Circulation Kit, page 36) S Air Line Shutoff Valve U Proportioner Air Supply Line W Air Filter/Separator AR Air Regulator (part of Reactor, page 10) BV Bleed-Type Master Air Valve (part of Reactor, page 10) W G Q K M J J G Q K U R L M AR BV A J G D E G P R F C* B * Shown exposed for clarity. Wrap with tape during operation. FIG. 1: Typical Installation, with circulation (246037 Air Powered Reactor Shown) TI3675a 8 309812G

Typical Installation, without circulation Typical Installation, without circulation Key for FIG. 2 A Reactor Proportioner B Heated Hose (see page 36) C Fluid Temperature Sensor (FTS) D Heated Whip Hose (see page 36) E Fusion Spray Gun (see page 36) F Gun Air Supply Hose G Feed Pump Air Supply Lines (part of Air Supply Kit, page 36) H Waste Containers J Fluid Supply Lines K Feed Pumps (see page 36) L Agitator M Desiccant Dryer (part of Return Tube Kit, page 36) N Bleed Lines P Gun Fluid Manifold (part of Fusion gun) Q Air Quick-Disconnect (part of Circulation Kit, page 36) S Hydraulic Supply Line T Hydraulic Return Line V Hydraulic Power Supply, with enclosed return filter W Air Filter/Separator HS Hydraulic Shutoff Valve (part of Reactor, page 10) W K J Q G M K V S HS L A G J D T N E H G F H P C* B * Shown exposed for clarity. Wrap with tape during operation. FIG. 2: Typical Installation, without circulation (246040 Hydraulic Powered Reactor Shown) TI3697a 309812G 9

Component Identification Component Identification Key for FIG. 3 AR Air Regulator BA Component A Pressure Relief Outlet BB Component B Pressure Relief Outlet BV Bleed-Type Master Air Valve CC Cycle Counter EC Electrical Cord Strain Relief FA Component A Fluid Manifold Inlet (behind manifold block) FB Component B Fluid Manifold Inlet FH Fluid Heaters (behind shroud) FM Reactor Fluid Manifold GA Component A Pressure Gauge GB Component B Pressure Gauge HA Component A Hose Connection HB Component B Hose Connection HC Heated Hose Electrical Connector HR Hydraulic Return Fitting, 1 npt(f) HS Hydraulic Shutoff Valve, 3/4 npt(f) MP Main Power Switch PA Component A Pump PB Component B Pump PM Pump Motor RS Red Heat Stop Button SA Component A PRESSURE RELIEF/SPRAY Valve SB Component B PRESSURE RELIEF/SPRAY Valve SC Fluid Temperature Sensor Cable TC Temperature Control Display UA Component A Fluid Inlet Strainer UB Component B Fluid Inlet Strainer VA Component A Fluid Inlet Valve VB Component B Fluid Inlet Valve Hydraulic Reactor Air-Powered Reactor HR HS FH TC RS CC AR BV FH TC RS CC PM PM FM FM PA SC PA SC VA UA HC VA UA HC VB UB TI3582b PB Detail of Reactor Fluid Manifold SA GA GB VB Detail of Main Power Switch (right side of unit) MP UB PB TI3669b FA BA SB EC FB HA HB BB TI3592a TI2500a-1 FIG. 3: Component Identification 10 309812G

Controls and Indicators Controls and Indicators Heater Power Indicators Heater Displays Zone A Arrow Keys Zone B Arrow Keys A B Heater A On/Off Key Heater B On/Off Key Hose Zone Arrow Keys F Hose Heater On/Off Key 1234567 Actual Temperature Key C Temperature Scale Keys Cycle Counter Reset Button Target Temperature Key FIG. 4. Controls and Indicators Actual Temperature Key/LED Temperature Arrow Keys Press to display actual temperature. Target Temperature Key/LED Press to display target temperature. Temperature Scale Keys/LEDs Press, then press or to adjust temperature settings in 1 degree increments. Temperature Displays Show actual temperature or target temperature of heater zones, depending on selected mode. Defaults to actual at startup. Range is 32-190 F (0-88 C) for A and B, 32-180 F (0-82 C) for hose. Press F or C to change temperature scale. 309812G 11

Controls and Indicators Heater Zone On/Off Keys/LEDs Press to turn heater zones on and off. Also clears heater zone diagnostic codes, see page 33. LEDs are on steady when heater zones are powering up. Begin flashing as heat reaches targets. CB2 20 A Transformer Primary CB3 25 or 40 A* Heater A CB4 25 or 40 A* Heater B CB5 20 A Not Used * Depending on model. LEDs will also flash if cutback point is reached. Main Power Switch Located on right side of unit, page 10. Turns Reactor power ON and OFF. Does not turn heater zones or pumps on. CB1 CB2 CB3 CB4 CB5 TI2514A Red Stop Button For wiring and cabling, see repair manual. Located between temperature control panel and cycle counter panel, page 10. Press to shut off heater zones only. Does not stop air or hydraulic power to pumps. Use main power switch to shut off all power to heat control box. Close red-handled valve (BV or HS, page 10) to shut off power to motor. Cycle Counter Displays cycle count. To clear counter, press reset button. Circuit Breakers WARNING Read warnings, page 6. Located inside Reactor cabinet. Ref. Size Component CB1 50 A Hose/Transformer Secondary 12 309812G

Isocyanate Hazard Isocyanate Hazard Spraying materials containing isocyanates creates potentially harmful mists, vapors, and atomized particulates. Read material manufacturer s warnings and material MSDS to know specific hazards and precautions related to isocyanates. Prevent inhalation of isocyanate mists, vapors, and atomized particulates by providing sufficient ventilation in the work area. If sufficient ventilation is not available, a supplied-air respirator is required for everyone in the work area. To prevent contact with isocyanates, appropriate personal protective equipment, including chemically impermeable gloves, boots, aprons, and goggles, is also required for everyone in the work area. Moisture Sensitivity of Isocyanates Isocyanates (ISO) are catalysts used in two component foam and polyurea coatings. ISO will react with moisture (such as humidity) to form small, hard, abrasive crystals, which become suspended in the fluid. Eventually a film will form on the surface and the ISO will begin to gel, increasing in viscosity. If used, this partially cured ISO will reduce performance and the life of all wetted parts. Use moisture resistant hoses. The component A (ISO) hose must be constructed of polyethylene (PE), PTFE, polyolefin, or moisture-proof rubber compounds. Dry hoses before use. Never use reclaimed solvents, which may contain moisture. Always keep solvent containers closed when not in use. Spray Adjustments Flow rate, atomization, and amount of overspray are affected by four variables. Fluid pressure setting. Too little pressure results in an uneven pattern, coarse droplet size, low flow, and poor mixing. Too much pressure results in excessive overspray, high flow rates, difficult control, and excessive wear. Fluid temperature. Similar effects to fluid pressure setting. The A and B temperatures can be offset to help balance the fluid pressure. Mix chamber size. Choice of mix chamber is based on desired flow rate and fluid viscosity. Cleanoff air adjustment. Too little cleanoff air results in droplets building up on the front of the nozzle, and no pattern containment to control overspray. Too much cleanoff air results in air-assisted atomization and excessive overspray. The amount of film formation and rate of crystallization varies depending on the blend of ISO. To prevent exposing ISO to moisture: Always use a sealed container with a desiccant dryer in the vent, or a nitrogen blanket. Never store ISO in an open container. Keep the wet-cup of the pump filled with Graco ISO pump oil, Part No. 217374. The lubricant creates a barrier between the ISO and the atmosphere. 309812G 13

Setup Setup 1. Locate Reactor a. Locate Reactor on a level surface. b. Do not expose Reactor to rain. c. To mount on truck, bolt mounting feet of Reactor to truck bed. See page 37. TI3582b 14 309812G

Setup 2. Electrical requirements See TABLE 1. Does not include air compressor or hydraulic power supply. WARNING Installing this equipment requires access to parts which may cause electric shock or other serious injury if work is not performed properly. Have a qualified electrician connect power and ground to main power switch terminals, see page 16. Be sure your installation complies with all National, State and Local safety and fire codes. Part No. Table 1: Electrical Requirements (kw/full Load Amps) Model A-XP SERIES Voltage (phase) Full Load Peak Amps* System Watts** 246639 A-XP2 230V (1) 62 14,540 246752 A-XP2 230V (3) 40 14,540 246753 A-XP2 380V (3) 22 14,540 HT SERIES (Heat Package Only) 246365 HT-6.0 230V (1) 44 10,340 246760 HT-6.0 230V (3) 27 10,340 246761 HT-6.0 380V (3) 18 10,340 246607 HT-10.2 230V (1) 62 14,540 246762 HT-10.2 230V (3) 40 14,540 246763 HT-10.2 380V (3) 22 14,540 246364 HT-15.3 230V (1) 84 19,640 246764 HT-15.3 230V (3) 57 19,640 246765 HT-15.3 380V (3) 33 19,640 * Full load amps with all devices operating at maximum capabilities. Fuse requirements at various flow rates and mix chamber sizes may be less. ** Total system watts for all units, using 310 ft (94.6 m) hose. 309812G 15

Setup 3. Connect electrical cord Power cord is not supplied. See TABLE 2. Use 5/32 or 4 mm hex allen wrench to make connections. Table 2: Power Cord Requirements Cord Specification Part No. Model AWG (mm 2 ) 246639 A-XP2 6 (13.3), 2 wire + ground 246752 A-XP2 8 (8.4), 3 wire + ground 246753 A-XP2 10 (5.3), 4 wire + ground 246365 HT-6.0 8 (8.4), 2 wire + ground 246760 HT-6.0 10 (5.3), 3 wire + ground 246761 HT-6.0 12 (3.3), 4 wire + ground 246607 HT-10.2 6 (13.3), 2 wire + ground 246762 HT-10.2 8 (8.4), 3 wire + ground 246763 HT-10.2 10 (5.3), 4 wire + ground 246364 HT-15.3 4 (21.2), 2 wire + ground 246764 HT-15.3 8 (8.4), 3 wire + ground 246765 HT-15.3 8 (8.4), 4 wire + ground WARNING b. 230V, 3 phase: Connect power leads to L1, L2, and L3. Connect green to ground (GND). L1 L2 L3 GND c. 380V, 3 phase: Connect power leads to L1, L2, and L3. Connect neutral to N. Connect green to ground (GND). GND TI3248b Read warnings, page 6. a. 230V, 1 phase: Connect power leads to L1 and L2, and green to ground (GND). L1 L2 L3 N TI2725b GND L1 L2 TI2515c 16 309812G

Setup 4. Connect power source to motor b. Seal component A drum and use desiccant dryer (M) in vent. a. Air powered models: See FIG. 1. Connect air supply line (U) to air regulator kit inlet. See Technical Data on page 38 for inlet sizes, recommended hose sizes, and air consumption requirements. b. Hydraulic powered models: Hydraulic shutoff valve (HS, FIG. 3 on page 10) may be disconnected for shipping. Connect valve to hydraulic inlet fitting before connecting hydraulic supply line. c. Install agitator (L) in component B drum, if necessary. d. Inlet valve/strainer assemblies may be disconnected for shipping. Connect to pump fluid inlets, then connect supply hoses (J) from feed pumps to Reactor fluid inlet valves (VA, VB). VA See FIG. 2. Connect hydraulic supply line (S) to shutoff valve (HS). Connect return line (T) to return fitting. See Technical Data on page 38 for fitting sizes, recommended hose sizes, and hydraulic flow and consumption requirements. J VB TI3590b Typical hydraulic power supply will have: pressure compensated piston pump adjustable pressure range from 300-1200 psi (2.1-8.4 MPa, 21-84 bar) suction strainer return line filter air bleed valve pressure gauge case drain cooler appropriate motor starter. Supply hoses from feed pumps should be 3/4 in. (19 mm) ID minimum. Model HT heat packages only: connect proportioner hoses to 1/2 npt(f) connections on heater inlet blocks. 5. Connect feed pumps a. Install feed pumps (K) in component A and B supply drums. See FIG. 1 and FIG. 2, pages 8 and 9. 309812G 17

Setup 6. Connect pressure relief lines WARNING SA a. Recommended: Connect air purge hose (R) to relief fittings (BA, BB) of both PRESSURE RELIEF/SPRAY valves. Route hose back to component A and B drums. Also see FIG. 1, page 8. SB Do not install shutoffs downstream of the PRESSURE RELIEF/SPRAY valve outlets (BA, BB). The valves function as overpressure relief valves when set to SPRAY. Lines must be open so valves can automatically relieve pressure when Reactor is operating. R R BA BB TI3589a b. Alternately: Secure supplied bleed tubes (N) in grounded, sealed waste containers (H). See FIG. 2, page 9. 18 309812G

Setup 7. Install Fluid Temperature Sensor (FTS) c. Connect whip hose ground wire (U) to ground screw on underside of FTS. The Fluid Temperature Sensor (FTS) is supplied. Install FTS between main hose and whip hose. d. Connect main hose (B) to FTS (C). CAUTION To prevent damage to probe, do not kink or excessively bend whip hose. Do not coil hose tighter than the minimum bend radius of 3 ft (0.9 m). Do not subject hose to excessive weight, impact, or other abuse. a. Carefully extend FTS probe (S). Do not bend or kink probe. Insert in component A (ISO) side of main hose (B). b. Connect FTS (C) to whip hose (D). e. Connect electrical connectors (V). Secure connections with plastic ties (W). f. Connect air hose (F) to whip air hose (X). g. Connect main hose cable (Y) to FTS. Slide insulator sleeves over connection. Leave slack (Z) in cables as stress relief, to prevent cable failure. C U W V Y D Z V S X F B TI9582a FIG. 5. Install Fluid Temperature Sensor (FTS) 309812G 19

Setup 8. Connect heated hose See 309572 for detailed instructions for Graco heated hoses. d. Connect cables (Y). Connect electrical connectors (V). Secure with plastic ties. Be sure cables have slack when hose bends. Wrap cable and electrical connections with electrical tape. CAUTION The fluid temperature sensor (FTS) and whip hose must be used with heated hose, see page 19. Hose length, including whip hose, must be 60 ft (18.3 m) minimum. Y V a. Turn main power OFF. TI2727A b. Assemble heated hose sections, FTS, and whip hose. 9. Close gun fluid manifold valves A and B c. Connect A and B hoses to A and B outlets on Reactor fluid manifold (FM). Hoses are color coded: red for component A (ISO), blue for component B (RES). Fittings are sized to prevent connection errors. FM A TI2411A B TI2726A 20 309812G

Setup 10. Connect whip hose to gun fluid manifold Do not connect manifold to gun yet. 50 ft 100 ft 150 ft 200 ft 250 ft 300 ft TI2417A 11. Pressure check hose See hose manual. Pressure check for leaks. If no leaks, fully wrap hose and electrical connections with tape to protect from damage. 12. Set transformer wire taps WARNING Read warnings, page 6. Turn main power switch OFF. Transformer tap wire connections vary depending on length of heated hose. See FIG. 6. Verify that tap wire connections are correct. Hose Length* ft (m) Tap Terminal Label (ft) 60-85 (18.3-25.9) 50 110-135 (33.5-41.2) 100 160-185 (48.8-56.4) 150 210-235 (64.1-71.7) 200 260-285 (79.3-86.9) 250 310 (94.6) 300 TI3470a * Length includes heated fluid hose and whip hose. FIG. 6: Transformer Wire Taps 309812G 21

Setup 13. Ground system WARNING WARNING Read warnings, page 6. a. Reactor: is grounded through power cord. See page 16. Pump rod and connecting rod move during operation. Moving parts can cause serious injury such as pinching or amputation. Keep hands and fingers away from wet-cups (R) during operation. Shut off pumps before filling wet cups. Check pump wet-cups (R) daily. Keep filled with Graco ISO pump oil, Part No. 217374, to keep air or moisture from reacting with fluids. b. Spray gun: connect whip hose ground wire to FTS, page 19. Do not disconnect wire or spray without whip hose. c. Fluid supply containers: follow your local code. d. Object being sprayed: follow your local code. e. Solvent pails used when flushing: follow your local code. Use only metal pails, which are conductive, placed on a grounded surface. Do not place pail on a nonconductive surface, such as paper or cardboard, which interrupts grounding continuity. R TI3582-3 f. To maintain grounding continuity when flushing or relieving pressure, hold a metal part of spray gun firmly to the side of a grounded metal pail, then trigger gun. 14. Fill wet-cups 22 309812G

Startup Startup WARNING Do not operate Reactor without all covers and shrouds in place. 1. Fluid Temperature Sensor (FTS) Calibration Calibrate the FTS ONLY at initial startup (the first time the unit is operated) and any time the hose length changes. a. Before turning on the unit, ensure all hoses and cables are properly connected. To ensure that the FTS in the hose is at the same temperature as the heaters, keep heat off and store the hose FTS near the machine for several minutes. b. While holding down the temperature unit button (Fahrenheit - F or Celsius - C ) turn the Reactor main power ON. c. Hold the temperature unit button until temperature is shown on the display. The fluid temperature sensor is now correctly calibrated. a. Check that Setup steps 1-14 are complete, pages 14-22. b. Turn on component B agitator, if used. c. Turn both PRESSURE RELIEF/SPRAY valves (SA, SB) to SPRAY. After changing drums, set PRESSURE RELIEF/SPRAY valves to PRESSURE RELIEF. This provides sufficient fluid velocity to purge air from pumps and heaters. d. Open fluid inlet valves (VA, VB). VA SA SB TI3591a 2. Load fluid with feed pumps The Reactor is tested with oil at the factory. If necessary, flush out the oil with a compatible solvent before spraying. See page 35. Equipment and hoses contain some residual moisture. Do not load with isocyanate and leave unused for a long period. Pumping and spraying helps remove moisture from system. VB e. Start feed pumps. TI3590b 309812G 23

Startup WARNING c. Press. Always provide two grounded waste containers to keep component A and component B fluids separate. f. Hold gun fluid manifold over two grounded waste containers. Open fluid valves A and B until clean, air-free fluid comes from valves. Close valves. d. To set A heat zone target temperature, press or until display shows desired temperature. Repeat for B and zones. heat zone target cannot be set higher than A or B heat zone targets. TI2484A For zone only, if FTS is disconnected at 3. Set temperatures startup, display will show hose current (0A). See step h, page 25. WARNING e. Press to display actual temperatures. This equipment is used with heated fluid, which can cause equipment surfaces to become very hot. To avoid severe burns: Do not touch hot fluid or equipment. Allow equipment to cool completely before touching it. Wear gloves if fluid temperature exceeds 110 F (43 C). WARNING Read warnings, page 6. Do not turn on hose heat without fluid in hoses. f. Turn on heat zone by pressing a. Turn main power ON. b. Press F or C to change temperature scale.. Preheat hose (15-60 min). Indicator will flash very slowly when fluid reaches target temperature. Display shows actual fluid temperature in hose near FTS. 24 309812G

Startup WARNING 4. Set pressure Read warnings, page 6. Thermal expansion can cause overpressurization, resulting in equipment rupture and serious injury, including fluid injection. Do not pressurize system when preheating hose. g. Turn on A and heat zones B a. Turn on air or hydraulic pressure to motor. b. Adjust motor input pressure until fluid pressure gauges (GA, GB) show desired fluid pressure. by pressing for each zone. GA GB h. Manual current control mode only: WARNING TI3591a Read warnings, page 6. When in manual current control mode, monitor hose temperature with thermometer. Install per instructions below. Thermometer reading must not exceed 160 F (71 C). If FTS is disconnected or display shows diagnostic code E04, turn main power switch OFF then ON to clear diagnostic code and enter manual current control mode. display will show current to hose. Current is not limited by target temperature. To prevent overheating, install hose thermometer close to gun end, within operator view. Insert thermometer through foam cover of A component hose so stem is next to inner tube. Thermometer reading will be about 20 F less than actual fluid temperature. If thermometer reading exceeds 160 F (71 C), reduce current with key. 309812G 25

Spraying Spraying 1. Engage gun piston safety lock. 4. Set PRESSURE RELIEF/SPRAY valves (SA, SB) to SPRAY. SA SB TI2409A 2. Close gun fluid manifold valves A and B. TI3591a 5. Check that heat zones are on and temperatures are on target, page 24. 6. Check for proper pressure balance, page 25. TI2728A 3. Attach gun fluid manifold. Connect gun air line. Open gun air line valve (W). W TI2543A 26 309812G

Spraying 7. Open gun fluid manifold valves A and B. 8. Disengage gun piston safety lock. TI2410A TI2414A 9. Test spray onto cardboard for several seconds. Adjust pressure and temperature to get desired results. 10. Equipment is ready to spray. 309812G 27

Shutdown Shutdown 1. Shut off,, and heat zones. A B 4. Turn main power OFF. 2. Trigger gun to park pumps at bottom of stroke. 3. Fill wet-cups, page 22. 5. Close red-handled valve (BV or HS, page 10) to shut off power to motor. 6. Relieve pressure, page 29. 28 309812G

Pressure Relief Procedure Pressure Relief Procedure 1. Relieve pressure in gun and perform gun shutdown procedure. See gun manual. 6. Engage gun piston safety lock. 2. Close gun fluid manifold valves A and B. TI2409A 7. Disconnect gun air line and remove gun fluid manifold. TI2421A 3. Shut off feed pumps and agitator, if used. 4. Check that red-handled valve (BV or HS, page 10) is closed, to shut off power to motor. 5. Turn PRESSURE RELIEF/SPRAY valves (SA, SB) to PRESSURE RELIEF. Route fluid to waste containers or supply tanks. Ensure gauges drop to 0. Pump throat seals work best under pressure. Close fluid inlet valves (VA, VB) when Reactor is depressurized, to prevent drum head pressure from leaking past pump rod seals. 8. Close fluid inlet valves (VA, VB). TI2554A SA SB VA TI3593a VB TI3698b 309812G 29

Fluid Circulation Fluid Circulation Circulation Through Reactor Use this procedure to purge air from pumps, heaters, and lines. WARNING 3. Set PRESSURE RELIEF/SPRAY valves (SA, SB) to PRESSURE RELIEF. SA BA SB Read warnings, page 6. Do not circulate fluid containing a blowing agent without consulting with your material supplier regarding fluid temperature limits. To circulate through gun manifold and preheat hose, see page 31. 1. Load fluid with feed pumps, page 23. WARNING BB TI3593a 4. Circulate fluid with feed pumps until air is purged through pumps. 5. Set PRESSURE RELIEF/SPRAY valves (SA, SB) to SPRAY. Do not install shutoffs downstream of the PRESSURE RELIEF/SPRAY valve outlets (BA, BB). The valves function as overpressure relief valves when set to SPRAY. Lines must be open so valves can automatically relieve pressure when machine is operating. SA SB TI3591a 2. Route air purge lines back to respective component A or B supply drum. Use hoses rated at the maximum working pressure of this equipment. See FIG. 1, page 8. 30 309812G

Fluid Circulation Circulation Through Gun Manifold WARNING 2. Connect high pressure circulation lines (R) to circulation manifold. Route circulation lines back to respective component A or B supply drum. Use hoses rated at the maximum working pressure of this equipment. Read warnings, page 6. Do not circulate fluid containing a blowing agent without consulting with your material supplier regarding fluid temperature limits. Circulating fluid through the gun manifold allows rapid preheating of hose. 3. Follow Load fluid with feed pumps, page 23. 4. Turn main power ON. 1. Install gun fluid manifold (P) on Part No. 246362 accessory manifold circulation kit (W). 5. Set temperature targets, see page 24. Turn on A B P,, and heat zones by pressing. W R 6. Press to display actual temperatures. TI4063a 7. Circulate fluid at lowest possible pressure until temperatures reach targets. 309812G 31

Fluid Circulation 32 309812G

Diagnostic Codes Diagnostic Codes Temperature Control Diagnostic Codes Temperature control diagnostic codes E01 through E05 appear on temperature display. These alarms turn off heat. Turn main power OFF then ON to clear. See repair manual for corrective action. Code Code Name Alarm Zone No. 01 High fluid temperature Individual 02 High hose current Hose only 03 No hose current with hose heater on Hose only 04 FTS or thermocouple not connected Individual 05 Board overtemperature All For hose zone only, if FTS is disconnected at startup, display will show hose current 0A. 309812G 33

Maintenance Maintenance Check pump wet-cups (R) daily, page 22. Keep filled with Graco ISO pump oil, Part No. 217374, to keep air or moisture from reacting with fluids. If oil on rods appears milky from crystallization, wipe rods clean and refill wet-cups with fresh ISO pump oil. Remove plugs (S) and clean fluid inlet screens as needed. S TI3590b R TI3582a-3 Keep component A from exposure to moisture in atmosphere, to prevent crystallization. Store Reactor with pumps at bottom of stroke. See page 28. Clean gun mix chamber ports regularly. See gun manual. Clean gun check valve screens regularly. See gun manual. Use compressed air to prevent dust buildup on control boards, fan, and motor (under shield). 34 309812G

Flushing Flushing WARNING Read warnings, page 6. Flush equipment only in a well-ventilated area. Do not spray flammable fluids. Do not turn on heaters while flushing with flammable solvents. Flush out old fluid with new fluid, or flush out old fluid with a compatible solvent before introducing new fluid. Use the lowest possible pressure when flushing. All fluid components are compatible with common solvents. Use only moisture-free solvents. To flush feed hoses, pumps, and heaters separately from heated hoses, set PRESSURE RELIEF/SPRAY valves (SA, SB) to PRESSURE RELIEF. Flush through bleed lines (N). SA N N SB TI3593a To flush entire system, circulate through gun fluid manifold (with manifold removed from gun). Always leave some type of fluid in system. Do not use water. 309812G 35

Accessories Accessories Feed Pump Kits Pumps, hoses, and mounting hardware to supply fluids to Reactor. Includes 246483 Air Supply Kit. See 309815. 246483 Air Supply Kit Hoses and fittings to supply air to feed pumps, agitator, and gun air hose. Included in feed pump kits. See 309827. 246978 Circulation Kit Return hoses and fittings to make circulation system. Includes two 246477 Return Tube Kits. See 309852. 246477 Return Tube Kit Desiccant dryer, return tube, and fittings for one drum. Two included in 246978 Circulation Kit. See 309852. Heated Hoses 50 ft (15.2 m) and 25 ft (7.6 m) lengths, 1/4 in. (6 mm), 3/8 in. (10 mm), or 1/2 in. (13 mm) diameter, 2000 psi (14 MPa, 140 bar) or 3500 psi (24 MPa, 241 bar). See 309572. Heated Whip Hoses 10 ft (3 m) whip hose, 1/4 in. (6 mm) or 3/8 in. (10 mm) diameter, 2000 psi (14 MPa, 140 bar) or 3500 psi (24 MPa, 241 bar). See 309572. Fusion Spray Gun Air purge gun, available in round or flat pattern. See 309550. Mechanical purge gun, available in round or flat pattern. See 309856. 246086 Data Reporting Kit Records actual temperature, temperature setpoint, actual pressure, cycles, and diagnostic code data from Reactor. Downloads data to PC with Microsoft Windows 98 or later. See 309814. 36 309812G

Dimensions Dimensions Dimension Model in. (mm) A A-25, A-XP2, A-XP2 2:1 A-50 H-50 49 (1245) 55 (1397) 53 (1346) 60.5 (1537) H-XP3 B All 35 (889) C All 36.5 (927) D All 25 (635) E All 27 (686) Dimension Model in. (mm) F All 11 (279) G (hole diameter) All 0.625 (16) Weight A-25, A-XP2 A-50 H-50 H-XP3 HT Series 400 lb (180 kg) 480 lb (216 kg) 475 lb (214 kg) 485 lb (218 kg) 333 lb (150 kg) Front View Side View A B C D Mounting Hole Dimensions E F G TI3700a 309812G 37

Technical Data Technical Data Category Maximum Fluid Working Pressure Maximum Input Pressure to Motor Data Model A-25: 1920 psi (13 MPa, 130 bar) Models A-50 and H-50: 2000 psi (14 MPa, 140 bar) Models A-XP2 2:1: 2000 psi (14 MPa, 140 bar) Models A-XP2 and H-XP3: 3000 psi (20.7 MPa, 207 bar) Models A-25, A-XP2, and A-XP2 2:1: 120 psi (0.82 MPa, 8.2 bar) air Model A-50: 75 psi (0.5 MPa, 5 bar) air Models H-50 and H-XP3: 1200 psi (8.4 MPa, 84 bar) oil Pressure Ratio Fluid:Air Model A-25: 16:1 Model A-XP2 2:1: 17.1:1 Model A-XP2: 25:1 Model A-50: 26:1 Fluid:Oil Model H-50: 1.65:1 Air Inlet Recommended Air Supply Hose Size Air Consumption Model H-XP3: 2.76:1 Models A-25, A-XP2, and A-XP2 2:1: 1/2 npsm(f) Model A-50: 3/4 npsm(f) Models A-25, A-XP2, and A-XP2 2:1: 1/2 in. (13 mm) ID minimum Model A-50: 3/4 in. (19 mm) ID minimum Model A-25: 40 scfm at 120 psi (0.82 MPa, 8.2 bar), 1.6 gpm (6.1 lpm) Model A-XP2: 40 scfm at 120 psi (0.82 MPa, 8.2 bar), 1.0 gpm (3.8 lpm) Model A-XP2 2:1: 40 scfm at 120 psi (0.82 MPa, 8.2 bar), 1.5 gpm (5.7 lpm) Hydraulic Supply Inlet Hydraulic Return Outlet Recommended Hydraulic Hose Size Maximum Hydraulic Oil Flow Hydraulic Oil Consumption Model A-50: 80 scfm at 75 psi (0.5 MPa, 5 bar), 5.0 gpm (19 lpm); 35 scfm at 75 psi (0.5 MPa, 5 bar), 2.0 gpm (7.6 lpm) Models H-50 and H-XP3: 3/4 npt(f) Models H-50 and H-XP3: 1 in. npt(f) Supply Hose: 3/4 in. (19 mm) ID minimum Return Hose: 1 in. (25 mm) ID minimum Models H-50 and H-XP3: 10 gpm (3.8 lpm), 50 cycles/min Models H-50 and H-XP3: 1.0 gpm (38 lpm) per 5 cycles 38 309812G

Technical Data Category Fluid Inlets Fluid Outlets Fluid Circulation Ports Maximum Fluid Temperature Maximum Output (10 weight oil at ambient temperature) Output per Cycle (A and B) Line Voltage Requirement Data Models A-25, A-XP2, A-XP2 2:1, and H-XP3: 3/4 npt(f) Models A-50 and H-50: 1 npt(f) Model HT heat packages: 1/2 npt(f) on heater inlet blocks Component A (ISO): #8 JIC (3/4-16 unf), with #5 JIC adapter Component B (RES): #10 JIC (7/8-14 unf), with #6 JIC adapter 1/4 npsm(m), with plastic tubing, 250 psi (1.75 MPa, 17.5 bar) maximum 190 F (88 C) Model A-25: 25 lb/min (11 kg/min) at 75 cycles/min Models A-50 and H-50: 50 lb/min (22.5 kg/min) at 45 cycles/min Model A-XP2: 1.5 gpm (5.7 liter/min) at 78 cycles/min Model A-XP2 2:1: 1.5 gpm (5.7 liter/min) at 60 cycles/min Model H-XP3: 3.6 gpm (13.7 liter/min) at 50 cycles/min Model A-25: 0.031 gal. (0.117 liter) Models A-50 and H-50: 0.114 gal. (0.431 liter) Model A-XP2: 0.0193 gal. (.073 liter) Model A-XP2 2:1: 0.02895 gal. (0.110 liter) Model H-XP3: 0.072 gal. (0.274 liter) 230V 1 phase and 230V 3 phase units: 195-264 Vac, 50/60 Hz 380V 3 phase units: 338-457 Vac, 50/60 Hz Amperage Requirement See TABLE 1, page 15. Heater Power (A and B heaters, no hose) Sound Power, per ISO 9614-2 Sound Pressure, 1 m from equipment Wetted Parts Model HT-6.0: 6000 Watts Models A-25, A-XP2, A-XP2 2:1, and HT-10.2: 10200 Watts Models A-50, H-50, H-XP3, and HT-15.3: 15300 Watts Model A-25: 94.7 db(a) at 1000 psi (7 MPa, 70 bar), 3.0 gpm (11.4 lpm), 15 cpm Model A-50: 86.5 db(a) at 1000 psi (7 MPa, 70 bar), 3.0 gpm (11.4 lpm), 15 cpm Model A-XP2: 94.7 db(a) at 2000 psi (14 MPa, 140 bar), 0.5 gpm (1.9 lpm), 15 cpm Model A-XP2 2:1: 94.7 db(a) at 1370 psi (9.4 MPa, 94 bar), 0.75 gpm (2.8 lpm), 15 cpm Model H-50: 88 db(a) at 1000 psi (7 MPa, 70 bar), 3.0 gpm (11.4 lpm), 20 cpm Model H-XP3: 103 db(a) at 2000 psi (14 MPa, 140 bar), 0.5 gpm (1.9 lpm), 25 cpm Model A-25: 81 db(a) at 1000 psi (7 MPa, 70 bar), 3.0 gpm (11.4 lpm), 15 cpm Model A-50: 78.8 db(a) at 1000 psi (7 MPa, 70 bar), 3.0 gpm (11.4 lpm), 15 cpm Model A-XP2: 81 db(a) at 2000 psi (14 MPa, 140 bar), 0.5 gpm (1.9 lpm), 15 cpm Model A-XP2 2:1: 81 db(a) at 1370 psi (9.4 MPa, 94 bar), 0.75 gpm (2.8 lpm), 15 cpm Model H-50: 78 db(a) at 1000 psi (7 MPa, 70 bar), 3.0 gpm (11.4 lpm), 20 cpm Model H-XP3: 88 db(a) at 2000 psi (14 MPa, 140 bar), 0.5 gpm (1.9 lpm), 25 cpm Aluminum, stainless steel, zinc-plated carbon steel, brass, carbide, chrome, chemically resistant o-rings, PTFE, ultra-high molecular weight polyethylene Loctite is a registered trademark of the Loctite Corporation. 309812G 39

Graco Standard Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco s written recommendations. This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco. This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation. THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE. Graco s sole obligation and buyer s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale. GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties. In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise. FOR GRACO CANADA CUSTOMERS The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées. Graco Information TO PLACE AN ORDER, contact your Graco distributor, or call this number to identify the distributor closest to you: 1-800-328-0211 Toll Free 612-623-6921 612-378-3505 Fax All written and visual data contained in this document reflects the latest product information available at the time of publication. Graco reserves the right to make changes at any time without notice. This manual contains English. MM 309812 Graco Headquarters: Minneapolis International Offices: Belgium, China, Japan, Korea GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441 Copyright 2003, Graco Inc. is registered to I.S. EN ISO 9001 www.graco.com Revised 7/2008